Nature Technology innovation Future Hig h-tech materials manufactured using natural fibres
2 iNNovatioN made by sachsenrÖder.
_ guStav SaChSEnRödER invEntEd ContinuouS vulCanizEd fibRE. Innovation is the power to create something new. This capacity has a long history at Sachsenröder. Only a short while after establishing the company, Gustav-Heinrich Sachsenröder manufactured continuous vulcanized fibre at the beginning of the 20th century in a factory beside the river Wupper. He was the first to successfully use a sulphuric acid process.
_ SavutEC® and gESaduR® in uSE all ovER thE WoRld. HigH-tecH materials HigH-tecH More innovations were to follow. In over 125 years of company history, a broad range of vulcanized fibre products now with the brand name SAVUTEC ® has been developed. These are used in a variety of industries and applications all over the world. The product line is complemented by high-density thermosetting plastics under the brand name GESADUR ®.
_ ExPERiEnCE and REnEWablE RaW MatERialS. The development department constantly works on optimizing our high-yield products. sacHsenröder sacHsenröder The Sachsenröder company can rely on the technical competence and the vast experience of its employees and utilizes high-tech products one of the most important resources of our times in a precisely targeted way: renewable raw materials. Materials made by Sachsenröder are high-tech from nature – sustainable, pioneering and innovative by nature.
savutec® tHe eXtreme natural fibre. The basic material for vulcanized fi bre products is cotton fi bres. They belong to the group of renewable raw mate- rials. The raw paper that is made out of the plant fi bres is then parchmentized and thus becomes the vulcanized fi bre SAVUTEC®. Sachsenröder manufactures SAVUTEC® in a variety of qualities, precisely tailored to the applica- tion in question.
gesadur® tHe natural polymer. 60 % of GESADUR® consists of natural fi bre that Sachsen- röder uses for making a homogeneous polymer based on high-density thermosetting plastics. During the curing process its structure becomes extremely solid so that it can no longer be deformed. GESADUR® WN is a material of choice in the manufacture of support rollers in the wire stranding industry.
3 From plant Fibre to vulcanized F ibre. g Process
01 Cotton plant 02 Seed capsule of the cotton flower
tHe preliminary stage // raw paper. The basic material of the vulcanized fibre SAVUTEC® is cotton, and it is the cotton fibres that are processed or, more precisely, the 3-5mm long linter fibres. These consist of cellulose that is gained from the seed hair of the cotton flower. After the harvest, the cotton linters are mechanically cleaned, cooked and bleached. The paper
N ufacturi machine then forms the actual paper structure: For this purpose the cellulose is dissolved in water and made into a paper pulp. This pulp, which in the beginning consists of 99 % water, runs over an endless screed that dehydrates the pulp step by step. The rolled up raw paper sheet is parchmentized at Sachsenröder. Ma N
08 Washed, neutralized and cured 07 Manufactured vulcanized fibre, Savutec® vulcanized fibre still acid
4 materials H -tec Hig H
03 Extracted cotton linters, 04 Cotton linters, senröder unbleached bleached and cleaned H sac
parcHmentizing // savutec® vulcanized fibre. For parchmentizing, one or several layers of raw paper are pulled through a bath with concentrated sulphuric acid, wrung out and subsequently washed out in several baths with decreasing concentration. The acid ensures that the fibres of the cotton tie together anew. »Hydrate cellulose« forms on the surface. The sulphuric acid serves as a catalyser which is washed out completely (neutral pH factor). Subsequently, the vulcanized fibre Savutec® is cured, rolled up and packaged.
06 Parchmentizing process 05 Raw paper sheets
5 6 savutec® since 1855,butasamaterialonnaturalbasisitisincreasingly becomingthefocusofindustry. rubber whichisaprocess similartoparchmentizing rawpaper. Vulcanized fibre hasbeenknown Vulcanized fibre -thenameoriginatedfrom thevulcanizationofnaturalrubbertomakehard r s refined since1881. corresponding experience.Sachsenröderprovides thisexpertise-collected, expandedand its manypossiblevariationscanonlybeexploitedifyouhavespecialknowledgeandthe Vulcanized fibre hasthusproved tobeoneofthemostflexiblematerialsthatexist.However, _ With SAVUTEC _ _ matching colours. parchmentizing -tailored toanyapplication.Uponrequest, SAVUTEC various qualities.Thematerialproperties are determinedbythefibre qualityandthesetupof ExPERtiSE andEx Quality inM PR ediscover provenmaterial. avutec ov E n M at ® ERial onanatuR Sachsenröderoffers avulcanizedfibre ofthehighestqualityandwith any Q PERiEn ® ualitiES. CE. al ba SiS. SiS. Material saM ple ® isalsoavailablein
colour range // optional savutec® can be made in many colours. EnvironmEntal propE rtiEs
. natural product / renewable raw material . eco-friendly, eco-compatible, because it is a pH neutral cellulose product . nontoxic combustion products (except normal flue gas) . almost clean burning . extinguishing agent can be selected according to surroundings . high flexibility because of good re-climatizing
savutec properties
7 savutec® so strong. so Formable. so varied.
_ a vaRiEty of PRoPERtiES. SAVUTEC® is a strong, horn-like material that is very easily formed. The proprietary vulcanized fibre is hard, tough and wear-resistant. It convinces with its high mechanical strength and an extreme tear resistance.
_ a vaRiEty of aPPliCationS. What you can do with SAVUTEC ® is no less impressive: The material can be worked by bending, embossing, punching, cutting, drilling, milling, grinding, planing and glueing. The with corrugation applications are equally varied. SAVUTEC ® is particularly suitable as a carrier for abrasives and ® ensures that wood veneers do not peel off. It can be used in gaskets or serves as an insert in
X-ray raster screens to focus the rays. savutec
Colour / matErial strEngth wEight / struCturE
. several colours available . light . several thicknesses (from 0.07-1.0 mm) . horn-like . existing fi bre structure . sharp edges 01 . s a v u t e c 02 . s a v u t e c eXtreMe Material ProPerties Material eXtreMe
Forming / proCEssing propErtiEs stability / durability
. easy and precise bending, punching and embossing . high structural stability . good deep-drawing and forming properties . extreme tensile strength . very good post and soft-forming properties . high mechanical resistance . compressible . high wear resistance . resilient under repetitive strain . high adhesive strength (e.g. during bending in alternate directions) . coatable . grindable (producing smooth surfaces) 03 . s a v u t e c 04 . s a v u t e c
8 »tHe sHear tensile strengtH of savutec ® is sufficient to pass tHis sHear test.«
Imagine a 1.8 ton-Mercedes hanging from a piece of SAVUTEC® the size of a DIN A4 sheet. What would happen? Exactly – nothing! The enormous tensile strength of SAVUTEC® is suffi cient to pass this shear test. SAVUTEC® also proves to be capable of bearing above-average loads in industrial applications - and thus meets the highest demands!
aFFinity to warmth / hEat ElECtriCal propErtiEs
. high thermal stability even after treatment . good electrical properties . low thermal conductivity . non-conducting, electrical insulator . high ignition point . anti-static . fl ame burns slowly and evenly . clearly defi ned combustion beard 05 . s a v u t e c 06 . s a v u t e c
aFFinity to watEr / humidity storagE
. capillary effect . storable . impregnation possible . wet strength . optimal hygroscopic properties (retaining humidity) . suitable for osmotic purposes . suitable in sealings 07 . s a v u t e c 08 . s a v u t e c
9 savutec® Sm / SmS basis For high-yield grinding.
_ bEaRS RESPonSibility. If you wish to increase your performance to its peak you need a solid foundation. The leading manufacturers of flexible grinding services are fully aware of this. They appreciate SAVUTEC ® SM/SMS as a carrier as it bears responsibility.
_ foR high-yiEld abRaSivE diSkS. SAVUTEC® SM/SMS forms the basis for corundum coating of abrasive disks that achieve a circumferential speed of 80 m/sec. This means high demands on the tensile and adhesive strength as well as on the thermal resistance of the material. No problem with SAVUTEC ® SM/SMS! The values of the branded vulcanized fibre clearly exceed the standards required by the »Deutscher Schleifscheibenaussuss« [German Committee for Abrasive disks - DSA.] aPPlicatioNs
_ What SavutEC® SM/SMS offERS to uSERS: _ high stability after thermal treatment for resin curing _ high efficiency: structural stability allows making abrasive wheel with low percentage of vulcanized fibre _ high flexibility because of good re-climatizing properties _ eco-compatible because it is a pH neutral hydrate cellulose product
TenSile STrengTh TeST rePorT
15.000
13.500
12.000 ]
2 10.500
9.000
7.500
6.000
tensile strength [N/cm strength tensile 4.500
3.000
1.500
0 0 3,5 7,0 10,5 14,0 17,5 21,0 24,5 28,0
elongation at break [%]
10 abrasives and abrasive disks
Structure of an aBraSive diSK
savutec@ sm as carrier
binding agent
abrasive grains (corundum)
11 savutec® n sealing and insulation in any F orm.
_ MultiPlE uSES. A large variety of applications is the key feature of the SAVUTEC ® products. SAVUTEC® N serves as the best example. Vulcanized fibre is a component in many sealing and insulation elements that are in turn used in many different industrial areas. And the root cause is not least that SAVUTEC ® N has manifold processing options.
_ ElECtRiCal inSulation and foRMablE. It is its excellent physical and dielectric properties that distinguish SAVUTEC ® N. The versatile vulcanized fibre is not only electricity-insulated but it can also be bent, punched and embossed easily and precisely. The fact that the requirements pursuant to DIN 7737 are not only met but even exceeded in terms of values is part of the natural quality features of SAVUTEC ® N vulcanized fibre. NsPPlicatio a
_ What SavutEC® n offERS to uSERS: _ complies with DIN 7737 _ type VF3111 for general and mechanical purposes _ type VF3121 for electric purposes _ suitable for sealings and insulation _ suitable for bending, punching and embossing _ colours // blue-grey (standard), red, black
12 sealing and insulation
technology is a language with the discipline oF a grammar. you can use language as prose in daily liF e. and iF you are very good you can be a poet. ludwig mies van der rohe
13 savutec® DF compound and tool F unctions.
_ ExCEllEnt PRoPERtiES. Coloured decors make furniture, doors and car interiors more attractive. A special compound is needed to achieve the required effect: SAVUTEC ® DF – the vulcanized fibre for top decors that Sachsenröder provides in several qualities.
_ CaRRiER, SEPaRating foil, ContinuouS laMinatE. SAVUTEC® DF is suitable as a compound for laminates and decors or as a separating foil for deep-drawn elements. The flexible vulcanized fibre decor is available in the qualities Vulkament, ZL-Vulcanized fibre and smooth fibre. All products boast very favourable post and soft-forming properties, good deep-drawing suitability as well as high thermal resistance. Furthermore SAVUTEC ® DF can be used for making continuous laminates. NsPPlicatio a
_ What SavutEC® df offERS all uSERS: _ SavutEC® df / vM and SavutEC® df / zl _ especially suited for making shaped surfaces _ also suitable as separating foil for surface design _ in particular for decorative surfaces made on melamine resin and phenol resin base _ material thickness from 0.08 – 0.50 mm _ high adhesion _ good forming properties _ very good deep-drawing properties _ good thermal resistance, also after processing _ high mechanical and thermal interlaminar strength _ standard colours // white, light brown, brown, black
Savutec® aS S eparating foil for forming Savutec® a carrier for laminateS and decorative S urfaceS
tooling laminate savutec® savutec® Formed part pattern tooling
14 savutec® SmooTh Fibre solutions in medical technology.
SAVUTEC® smooth fibre features very good compound properties. This allows the manufacture of interesting material mixes that are used for the numerous purposes in medicine.
savutec® FT interesting properties in F iltration.
SAVUTEC® FT features special characteristic properties that are used in many areas of filtration applications. For example, SAVUTEC ® FT plays an important role in Osmosis filtration in particular (known as the Lenzing procedure).
15 future Markets what you can do with s avutec®!
_ innovationS foR thE MaRkEtS of thE futuRE. Sustainable, efficient, flexible: SAVUTEC® has everything that a modern company can wish for from a material. This is why vulcanized fibre products are successfully used in many industrial areas. But that is not all SAVUTEC® can do. SAVUTEC® offers enormous potential for development in new applications, uses and product ideas. In the industrial or technical field, in design or the craft sector - with SAVUTEC ® future topics become innovative solutions for the markets of the future. NsPPlicatio a
Furniture design sound prooF ing thermal insulation
lamp shades technology special packaging Fashion
16 V isions of a new economy, entrepreneurial spirit and the courage to do something new is a creative process. ulrich dietz
17 ideas traNsfer For which application do you need a solution?
SAVUTEC® - a material that provides plenty of food for ideas. Write down your wishes and requirements and find out together with Sachsenröder what can be made out of them.
gesadur® the natural polymer.
_ PolyMER With natuRal fibRE. To call GESADUR® a »natural polymer« may seem contradictory at first glance. But if you analyse this high-yield material more closely it very soon becomes clear: GESADUR ® consists of 60 % natural fibre. This means that the second Sachsenröder product line is also made on the basis of renewable raw material. erties
_ StRong aRguMEntS foR gESaduR GESADUR® is at its strongest when it needs to show strength: GESADUR ® can withstand tremendous forces! The reason for this strength is its three-dimensionally linked structure that forms during the curing process of the thermosetting plastic. With GESADUR® Sachsenröder provides a homogeneous, extremely compact material based on high-density thermosetting plastics, material that has proved itself in world-wide use.
Colour / matE rial thiC knEss
. yellow . becomes darker when exposed to uv light, no loss P + Pro Material in quality esadur 01 . g
Forming / proCEssing propE rtiEs stability / durability
. very good processing properties: machining, . low specific weight (1.4g/cm3) drilling, milling and sawing . high pressure resistance (350 n/mm2) esadur esadur 02 . g 03 . g
20 gesadur® witH stands enormous pressure.
GESADUR® can bear huge loads. When steel cables for modern suspension bridges are stranded, the machines run on rolls made of GESADUR® WN.
aFFinity to warmth / hE at ElECtriC propE rtiEs
. high thermal stability even after treatment . good dielectric properties . high ignition point . electricity insulation, electrical insulator . good thermal insulator . antistatic because of geSaclean . dimensional stability in great heat . stable in any climate 04 . gesadur . 04 gesadur . 05
storagE aFFinity to watE r / humidity
. storable . water and oil-repellent . no ageing . dirt-repellent because of geSaclean . resistant to termites . resistant to tropical climates . becomes darker in uv light, no loss in quality 06 . gesadur . 06 gesadur . 07
21 uNderrollers Made of gesadur® Wn reduce running noise, increase rotation speed.
_ no dEfoRMing of thE undERRollERS. Underrollers made of moulded laminates or steel show a high degree of wear and tear. During a prolonged shutdown of a machine the rollers may break or become deformed. Loud running noise and vibrations develop - the machine works inefficiently!
_ MoRE EffiCiEnCy With gESaduR® Wn. With GESADUR® WN a memory effect starts working: When machines start up again after a prolonged shutdown, the underrollers go back to their original shape. This means that rollers made of GESADUR ® WN do not flatten! GESADUR® WN allows you to increase the rotation speed of your machine and at the same time it reduces running noise. NsPPlicatio a
22
_ MouldS Max. // 207 | 234 | 262 | 287 | 322 | 362 | 407 | 412 | 492 | 552 | 632 | 707 | 1012 Max. width // 130 | 130 | 150 | 150 | 150 | 170 | 200 | 200 | 200 | 280 | 280 | 280 | 370
_ tEChni Cal data Pressure resistance // 350 N/mm2 | Dimensional stability Martens | 130° C Bending strength // 80 N/mm2 | Dielectric strength, processed | 15,5 kV (4 mm) Tensile strength // 45 N/mm2 | Surface resistance, processed | > 10 9 < 1010 Ohm (crosswise to pressing direction) Tensile strength // 7000-8000 N/mm2 | Abrasion value dry, against steel | 0,21 Specific weight // 1,4 g/cm2 | Abrasion value depending on lubricant | 0,21 Water absorption // 80 mg pursuant to DIN 53495/32
23 sPiNNiNg rollers Made of gesadur® Wn best Forming results.
_ foR SPun PaRtS With ExCEllEnt SuRfaCES. Spinning and profiling rollers made of GESADUR ® WN are designed for applications on high-yield machines as they are used in the manufacture of mirror-finish aluminium reflectors and spun parts made of ductile material. Using rollers made of GESADUR ® WN on your machines guarantees spun parts with excellent surfaces.
_ longER SERviCE lifE. Sachsenröder manufactures its spinning rollers on state-of-the-art CNC-lathes – with the highest precision. The high-density polymer GESADUR® WN provides a high surface quality and run true precision of 0.01 millimetres. Should GESADUR® WN spinning rollers show wear and tear, they can easily be reworked – and thus increase their service life significantly. NsPPlicatio a
24 the value oF a piece oF work is deFined by our own benchmarks and standards. kurt weidemann
25 sacHseNrÖder innovation is our tradition.
foundEd in 1881 in WuPPERtal. CloSEly tiEd to WuPPERtal. On 19 June 1881 Gustav-Heinrich Sachsenröder con- In the 3th generation Gustav-Adolf Sachsenröder and cluded a service agreement with parchment master Günther Sachsenröder continued developing new ma- Theodor Biesenkamp to set up a parchment paper terial: they enlarged the vulcanized fibre product range factory. The factory commenced operations on 1 Fe- with the now branded SAVUTEC® and continued to bruary in today‘s Wuppertal. expand the production facilities of GESADUR®. Since 1996 Dirk Sachsenröder has been managing the family business in the 4th generation. Just like his predeces- sors he feels strongly tied to »his« City of Wuppertal. With great personal commitment Dirk Sachsenröder promotes and supports the city and the industry loca- tion along the river Wupper.
EntREPREnEuRial and SoCial CoMMitMEnt. In influential functions Dirk Sachsenröder promo- tes development and networking of the industry lo- cation along the river Wupper. In the Federation of Entrepreneur‘s Associations (VBU) he is Chairman of the Board of the Employer‘s Association of the che- mical industry in the region Bergisches Land. He is a shareholder in the Technology Centre Wuppertal innovativE PRoduCtS fRoM WuPPERtal. (W-tec) and member of the Committee for Indus- Production started with parchment paper for try and Environment of the Chamber of Industry packaging and decoration. But Gustav-Heinrich and Commerce Wuppertal, Solingen, Remscheid. Sachsenröder soon recognized the particular advanta- Furthermore Dirk Sachsenröder is socially active at the ges of hydrate cellulose and soon began to manufac- Rotary Club Wuppertal-Süd. ture multi-layered parchment. This innovative power inspired his son Gustav Sachsenröder who became a pioneer. He was the first who managed to make conti- nuous vulcanized fibre.
Award »Living company culture«. Awarded by Peter Jung, Mayor of the City of Wuppertal.
26 27 ecoNoMy aNd ecology production in harmony with nature.
ECo-fRiEndly SulPhuRiC aCid PRoCEduRE. In contrast to the widespread zinc chloride process, the more sophisticated sulphuric acid process uses high- quality and renewable raw fibres. The sulphuric acid serves a catalyst in the parchmentizing process and is subsequently washed out of the final product comple- tely. Thus, SAVUTEC® is 100 % free of residues and equipped with particularly good mechanical material properties.
RESPonSibility foR Man and natuRE. As a family business it is only natural for Sachsenröder to assume responsibility for people and their environ- ment. This entails both quality products that are made in good working conditions and maintaining the basis of life for the next generation. This is the reason why Sachsenröder manufactures its vulcanized fibre pro- ducts with the eco-efficient sulphuric acid procedure – as the only company worldwide.
28 protecting the environment is an opportunity and not a burden we have to carry. helmut sihler
29 Quality MaNageMeNt the maxim For thinking and acting.
CERtifiEd PuRSuant to din En 9001. The basis for highest customer satisfaction is a consis- tent focus on quality work. It determines thinking and acting at Sachsenröder. All business processes are tied into a quality assurance system that is certifi ed pursu- ant to DIN EN ISO 9001. The quality of products and services is thus confi rmed and documented in every phase – from development to delivery.
high PRoduCt Quality, high availability. The trained employees in the quality assurance department make sure that product quality remains consistently high. They immediately detect, analyse and eliminate even the smallest devia- tions from predetermined parameters. Sophisticated statistical methods for assessing raw material, production and the fi nal product guarantee thorough control in any production phase. The most modern measuring technology ensures that stringent quality standards are being met. Materials management and logistics are controlled by state-of- the-art technology. This ensures our high availability and reliable delivery of SAVUTEC® and GESADUR®.
30 Quality is never a coincidence. it is always the result oF high goals, sincere eFFort, intelligent procedure and skilFul execution. will a. Foster
31 tHe iNNovatioN laboratory research partnership with u niversity oF wuppertal.
bEnEfitting fRoM thE PotEntial of SavutEC®. Embarking on new paths – Sachsenröder puts this mot- to of innovative companies into practice. University of Wuppertal and Dirk Sachsenröder jointly founded the innovations laboratory. Its aim is to further optimise the production process of SAVUTEC® and to fully exploit the enormous potential for development of SAVUTEC® vulcanized fibre.
Joint dEvEloPMEntS. Furthermore the laboratory is an ideal platform for development partnerships: All companies that wish to utilize SAVUTEC® for their applications are able to re- search and test these applications here. Sachsenröder shapes the future – jointly with its partners.
University of Wuppertal
32 you see things and ask »why?« but i dream oF things and say »why not?« george bernard shaw
33 iNterNatioNal focus sachsenrÖder is there For you, worldwide.
Your contact persons for SAVUTEC ® and GESADUR® are available worldwide. Please find a list of our sales representatives on the internet under »www.sachsenröder.com« under the menu item Contact/Sales Representatives.
coNtact do you have any Questions or ideas?
Would you like to develop new solutions together with Sachsenröder or learn more about the company and its products SAVUTEC® and GESADUR®? Just call us. Dirk Sachsenröder and his team are looking forward to talking to you.
SACHSENRÖDER GMBH & CO. KG Address Postfach 201622, 42216 Wuppertal Friedrich-Engels-Allee 143, 42285 Wuppertal, Germany Telephone +49.(0)202.28054-0 . Fax +49.(0)202.899937 Email [email protected] Internet www.sachsenroeder.com
34 imprint
Publisher SACHSENRÖDER GMBH & CO. KG – Wuppertal Design + concept www.pixelproduction.de – Wuppertal Photos Andreas Fischer – afi @wtal.de Image sources © Nero, Jan Stockmann/PIXELIO, Fotolia, istock-photo Text Ulrike Volkmann – Wuppertal Print production Druckerei Figge GmbH – Wuppertal
35 Sachsenröder GmbH & Co. KG Postfach 201622 . 42216 Wuppertal Friedrich-Engels-Allee 143 . 42285 Wuppertal // Germany Telephone +49.202.28054-0 . Facsimile +49.202.899937 . [email protected] www.sachsenroeder.com